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Housing-Air Distribution

WARNING: This page is about a different car, the 2009 Dodge Caliber. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors.
NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar.
Fig 1: HVAC Housing
GC0084670Courtesy of CHRYSLER LLC
  1. Remove the HVAC housing assembly and place it on a workbench. See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Removal .
  2. Remove the air distribution housing (2) from the HVAC housing (1). See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Removal .
  3. If equipped with the 2.0L diesel engine, remove the electric positive temperature coefficient (PTC) heater unit from the air distribution housing. See Heating and Air Conditioning/Cabin Heater/UNIT, Heater - Removal .
  4. Remove the heater core from the air distribution housing. See Heating and Air Conditioning/Plumbing/CORE, Heater - Removal .
    Fig 2: Temperature Control Cable and Levers
    GC0084673Courtesy of CHRYSLER LLC
  5. Remove the temperature control cable (1) from the left side of the air distribution housing (2). See Heating and Air Conditioning/Controls/CABLE, Temperature Control - Removal .
  6. Remove the screw and washer (5) that secures the blend door cable lever (6) to the air distribution housing and remove the cable lever.
    NOTE: To remove the blend door pivot lever, disengage the retaining tab and pull the lever straight out of the air distribution housing.
  7. Remove the blend door pivot lever (3) from the end of the blend door pivot shaft (4) and remove the pivot lever.
    Fig 3: Mode Door Cable and Cam
    GC0084674Courtesy of CHRYSLER LLC
  8. Remove the mode door cable (1) from the right side of the air distribution housing (2). See Heating and Air Conditioning/Controls/CABLE, Mode Door - Removal .
  9. Remove the screw and washer (3) that secure the mode door cam (4) to the air distribution housing and remove the cam.
    Fig 4: Parting Line and Retainers
    GC0082724Courtesy of CHRYSLER LLC
    NOTE: If any foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced.
  10. Carefully cut the two foam seals (1) along the parting line (2) of the two halves of the air distribution housing (3). If either seal is deformed or damaged, it must be replaced.
  11. Remove the five screws (4) and one metal clip (5) that secure the two halves of the air distribution housing together.
  12. Disengage the three plastic retaining tabs (6) that secure the two halves of the air distribution housing together and carefully separate the housing.
    Fig 5: Air Doors
    GC0082725Courtesy of CHRYSLER LLC
    NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.
  13. Disengage the air door(s) (1, 2, 3 and 4) from the mode door levers and remove the air doors from the air distribution housing (5).
    Fig 6: Mode Door Levers
    GC0082726Courtesy of CHRYSLER LLC
    NOTE: To remove the mode door levers, disengage the retaining tabs on the inside of the air distribution housing and pull the levers straight out of the housing.
  14. Remove the four mode door levers (1, 2, 3 and 4) from the right side of the air distribution housing (5).
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